Reassembly

EB62 MANUAL TRANSAXLE: MANUAL TRANSAXLE UNIT: REASSEMBLY

1. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

(a) Using SST and a press, press in a new front differential case front tapered roller bearing to the differential case.

SST : 09316-20011

SST : 09950-60010

09951-00580

09952-06010

SST : 09950-60020

09951-00910

SST : 09950-40011

09957-04010

SST : 09950-70010

09951-07100

(b) Using SST and a press, press in the front differential case front tapered roller bearing (outer race) together with the front differential oil baffle to the front transaxle case.

SST : 09950-60010

09952-06010

SST : 09950-60020

09951-00780

09951-00890

SST : 09950-70010

09951-07100

2. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

(a) Using SST and a press, press in a new front differential case rear tapered roller bearing to the differential case.

SST : 09316-20011

SST : 09950-60010

09951-00580

09952-06010

SST : 09950-60020

09951-00910

SST : 09950-40011

09957-04010

SST : 09950-70010

09951-07100

(b) Using SST, install the front differential case rear tapered roller bearing (outer race) together with the front differential case rear plate shim as shown in the illustration.

SST : 09950-60020

09951-00770

09951-00890

3. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

(a) Coat the differential case assembly with gear oil and install it to the front transaxle case.

(b) Install the manual transmission case with the 17 bolts.

Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)

(c) Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.

SST : 09564-50010

(d) Using SST and a torque wrench, measure the preload.

SST : 09564-50010

Standard preload (at starting):

New bearing
1.50 to 2.30 N*m (15 to 23 kgf*cm, 13 to 20 in.*lbf)

Used bearing
0.24 to 0.37 N*m (2.4 to 3.8 kgf*cm, 2.1 to 3.3 in.*lbf)

(e) If the preload is not as specified, replace the front differential case rear shim with one of a different thickness. Use the table below to select a front differential case rear shim which will ensure that the preload is within the specification.

Standard Shim Thickness:

HINT
* Select a thicker plate washer to increase the preload, or a thinner plate washer to decrease the preload.
* Make a memo as the torque values will be needed for the Adjust Output Shaft Bearing Preload procedure.
(f) Remove the 17 bolts and manual transmission case.

(g) Remove the differential case from the front transaxle case.

(h) Replace the installed front differential case rear plate washer with the one selected above.

4. INSTALL FRONT OUTPUT SHAFT BEARING

(a) Install the output shaft cover onto the front transaxle case.

NOTICE:
Insert the output shaft cover key into the case groove.

(b) Using SST and a press, press in the front output shaft bearing (outer race) to the front transaxle case.

SST : 09950-60010

09951-00620

09952-06010

SST : 09950-60020

09951-00710

SST : 09950-70010

09951-07100

5. INSTALL REAR OUTPUT SHAFT BEARING

(a) Using SST and a press, press in the rear output shaft bearing (outer race) together with the rear output shaft bearing shim to the manual transmission case.

SST : 09950-60010

09951-00490

09951-00620

09952-06010

SST : 09950-70010

09951-07150

6. ADJUST OUTPUT SHAFT BEARING PRELOAD

(a) Coat the differential case assembly with gear oil and install it to the front transaxle case.

(b) Coat the output shaft assembly with gear oil and install it to the front transaxle case.

Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)

(d) Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.

SST : 09564-50010

Text in Illustration:

(e) Using SST and a torque wrench, measure the preload (value A). Calculate the rear output shaft bearing shim value using the following formula.

SST : 09564-50010

Formula:

Value A - Differential side bearing preload = Output shaft bearing preload

Preload (at starting):

New bearing
2.80 to 5.60 N*m (29 to 57 kgf*cm, 25 to 50 in.*lbf)

Used bearing
2.31 to 4.62 N*m (24 to 47 kgf*cm, 20 to 41 in.*lbf)

(f) If the preload is not as specified, replace the rear output shaft bearing shim with one of a different thickness. Use the table below to select a rear output shaft bearing shim which will ensure that the preload is within the specification.

Standard Bearing Shim Thickness:

HINT
Select a thicker bearing shim to increase the preload, or a thinner bearing shim to decrease the preload.

(g) Remove the 17 bolts and manual transmission case.

(h) Remove the output shaft assembly from the front transaxle case.

(i) Remove the differential case from the front transaxle case.

(j) Replace the installed rear output shaft bearing shim with the one selected above.

7. INSTALL OUTER SHIFT LEVER OIL SEAL

(a) Using SST and a hammer, tap in a new outer shift lever oil seal to the manual transmission case.

SST : 09950-60010

09951-00280

SST : 09950-70010

09951-07100

Standard depth:

0.5 to 1.0 mm (0.0197 to 0.0393 in.)

(b) Coat the lip of the outer shift lever oil seal with MP grease.

8. INSTALL OUTER NO. 1 SHIFT LEVER

(a) Install the inner No. 1 shift lever, outer shift lever spacer and outer No. 1 shift lever to the manual transmission case.

(b) Using a (5 mm) pin punch and hammer, tap in the inner shift lever slotted spring pin to the inner No. 1 shift lever.

Standard depth:

-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

9. INSTALL NO. 1 OIL RECEIVER PIPE

(a) Install the No. 1 oil receiver pipe to the manual transmission case.

HINT
Make sure that the No. 1 oil receiver pipe fully contacts the manual transmission case.

10. INSTALL STRAIGHT PIN

(a) Using a plastic-faced hammer, tap in 5 new straight pins to the specified protrusion height.

Protrusion height:

10.5 to 11.5 mm (0.413 to 0.452 in.)

Text in Illustration:

11. INSTALL BREATHER PLUG

(a) Using SST and a hammer, tap in the breather plug to the front transaxle case.

SST : 09350-30020

09350-07110

12. INSTALL FRONT TRANSAXLE CASE OIL SEAL

(a) Using SST and a hammer, tap in a new front transaxle case oil seal to the front transaxle case.

SST : 09612-22011

Standard depth:

1.0 to 2.0 mm (0.0393 to 0.0787 in.)

(b) Coat the lip of the front transaxle case oil seal with MP grease.

13. INSTALL TRANSMISSION MAGNET

(a) Clean the transmission magnet and install it to the front transaxle case.

14. INSTALL INPUT SHAFT COVER

(a) Install the input shaft cover to the manual transmission case.

NOTICE:
Insert the input shaft cover key into the manual transmission case groove.

15. INSTALL REAR INPUT SHAFT BEARING SHIM

(a) Install the rear input shaft bearing shim onto the manual transmission case.

NOTICE:
Apply MP grease to the shim to prevent it from falling off the case during assembly.

(b) Measure the distance between the end of the manual transmission case and rear input shaft bearing shim (Dimension A).

Text in Illustration:

(c) Measure the distance between the end of the front transaxle case and installation surface of the front input shaft bearing (Dimension B).

(d) Measure the distance between both input shaft bearing outer races (Dimension C).

NOTICE:
Measure Dimension C when both bearings have no clearance.

(e) Calculate the rear input shaft bearing shim clearance using the following formula.

Formula:

(Dimension A + Dimension B) - Dimension C - Rear input shaft bearing shim thickness = Between 0 mm and 0.1 mm (0.00394 in.)

(f) If the clearance is not as specified, replace the rear input shaft bearing shim with one of a different thickness. Use the table below to select a rear input shaft bearing shim which will ensure that the clearance is within the specification.

Standard Rear Input Shaft Bearing Shim Thickness:

(g) Coat the selected rear input shaft bearing shim with MP grease, and then replace the installed rear input shaft bearing shim with the one selected above.

NOTICE:
Do not apply MP grease to the oil grooves.

16. INSTALL DIFFERENTIAL CASE ASSEMBLY

(a) Coat the differential case with gear oil and install it to the front transaxle case.

17. INSTALL INPUT SHAFT ASSEMBLY

(a) Apply gear oil to all sliding and rotating parts.

(b) Coat the No. 1 gear shift fork shaft with gear oil and install it onto the output shaft assembly.

Text in Illustration:

(d) Temporarily install the output shaft with No. 1 gear shift fork shaft to the input shaft assembly, and tie them with a rope or string.

(e) Install the input shaft assembly, output shaft assembly and 2 gear shift fork shaft assemblies to the front transaxle case.

18. INSTALL OUTER SELECT LEVER OIL SEAL

(a) Using SST and a hammer, tap in a new oil seal to the front transaxle case.

SST : 09950-60010

09951-00250

SST : 09950-70010

09951-07100

Standard depth:

0.5 to 1.0 mm (0.0197 to 0.0393 in.)

(b) Coat the lip of the outer select lever oil seal with MP grease.

19. INSTALL OUTER SELECT LEVER

(a) Install the outer select lever and inner select lever to the front transaxle case.

Text in Illustration:

HINT
Install the lever with its mark positioned outside of the front transaxle case.

(b) Coat the threads of the inner select lever bolt with adhesive and install it.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

20. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY

(a) Install the shift interlock plate and shift and select lever shaft assembly to the front transaxle case, and then turn them counterclockwise.

HINT
When installing the shift interlock plate, make sure to engage it with the inner select lever.

21. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY

(a) Coat the threads of the 2 bolts with adhesive, and then install the reverse shift arm bracket with the 2 bolts.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 17 Nm (173 kgf-cm, 12 ft-lbf)

22. INSTALL REVERSE SHIFT FORK

(a) Using a pin punch (5 mm) and a hammer, install the reverse shift fork slotted pin onto the No. 1 gear shift fork shaft.

Standard driven in depth:

-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

NOTICE:
Confirm the installation direction.

(b) Coat the No. 1 gear shift fork shaft assembly with gear oil and install it onto the front transaxle case.

23. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY

(a) Coat the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft with gear oil, and install them as shown in the illustration.

Text in Illustration:

NOTICE:
Using the bolt hole of the case for reference, align the I-groove mark of the reverse idler gear shaft within the range shown (approximately 20°).

HINT
Raise the edge of the reverse shift arm bracket assembly and install it to the reverse shift fork shaft assembly.

24. INSTALL MANUAL TRANSMISSION CASE SUB-ASSEMBLY

(a) Apply seal packing to the manual transmission case as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Seal packing diameter:

1.2 mm (0.0472 in.)

NOTICE:
* Remove any oil from the contact surfaces.
* Assemble the parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
(b) Push the outer No. 1 shift lever and install the manual transmission case.

HINT
Pushing the outer No. 1 shift lever allows the manual transmission case to be installed.

(c) Turn the outer No. 1 shift lever counterclockwise and then pull it.

(d) Install the manual transmission case with the 17 bolts.

Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)

25. INSTALL OUTER SHIFT LEVER E RING

(a) Install the outer shift lever E ring to the outer No. 1 shift lever.

26. INSTALL TRANSMISSION CASE OIL SEAL

(a) for LH Side:

(1) Using SST and a hammer, tap in a new transmission case oil seal to the manual transmission case.

SST : 09608-32010

SST : 09950-70010

09951-07100

Standard depth:

-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

NOTICE:
Do not damage the oil seal lip.

(2) Coat the lip of the transmission case oil seal with MP grease.

(b) for RH Side:

(1) Using SST and a hammer, tap in a new transmission case oil seal to the front transaxle case.

SST : 09710-30050

SST : 09950-70010

09951-07100

Standard depth:

-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

NOTICE:
Do not damage the oil seal lip.

(2) Coat the lip of the transmission case oil seal with MP grease.

27. INSTALL SHIFT DETENT BALL

(a) Install the 2 shift detent balls and 2 compression springs into the manual transmission case.

NOTICE:
Be careful not to drop the balls into the manual transmission case.

(b) Coat the threads of the 2 shift detent ball plugs with adhesive and install them using a (6 mm) hexagon socket wrench.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 22 Nm (224 kgf-cm, 16 ft-lbf)

(c) Install the shift detent ball and compression spring into the manual transmission case.

NOTICE:
Be careful not to drop the ball into the manual transmission case.

(d) Coat the threads of the shift detent ball plug with adhesive and install it using a (6 mm) hexagon socket wrench.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 22 Nm (224 kgf-cm, 16 ft-lbf)

28. INSTALL LOCK BALL PIN

(a) Install the lock ball pin and compression spring into the manual transmission case.

NOTICE:
Be careful not to drop the lock ball pin into the manual transmission case.

(b) Coat the threads of the plug with adhesive and install it using a (10 mm) hexagon socket wrench.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)

(c) Install the lock ball pin and compression spring into the manual transmission case.

NOTICE:
Be careful not to drop the lock ball pin into the manual transmission case.

(d) Coat the threads of the plug with adhesive and install it using a (10 mm) hexagon socket wrench.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)

29. INSTALL REVERSE IDLER GEAR SHAFT BOLT

(a) Coat the threads of the reverse idler gear shaft bolt with sealant and install it onto the manual transmission case with a new gasket.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

30. INSTALL RELEASE CYLINDER BLEEDER PLUG

(a) Install the release cylinder bleeder plug to the clutch release bleeder.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

31. INSTALL RELEASE CYLINDER BLEEDER PLUG CAP

(a) Install the release cylinder bleeder plug cap to the release cylinder bleeder plug.

32. INSTALL FLOOR SHIFT CONTROL SHAFT ASSEMBLY

(a) Install the floor shift control shaft assembly and wave washer with the nut.

Torque : 12 Nm (120 kgf-cm, 9 ft-lbf)

33. INSTALL FLOOR SHIFT SELECTING BELLCRANK ASSEMBLY

(a) Install the floor shift selecting bellcrank assembly and wave washer with the 2 bolts and nut.

Text in Illustration:

Bolt - Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)

Nut - Torque : 12 Nm (120 kgf-cm, 9 ft-lbf)

34. INSTALL FLOOR SHIFT CONTROL BELLCRANK DUST COVER

(a) Install the floor shift control bellcrank dust cover to the floor shift selecting bell crank assembly.

35. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY Installation

36. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY Installation

37. INSPECT CLUTCH PIPE LINE Installation

38. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY Installation

39. INSTALL CONTROL CABLE BRACKET

(a) Install the control cable bracket to the manual transmission case with the 2 bolts.

Torque : 18 Nm (188 kgf-cm, 14 ft-lbf)

40. INSTALL TRANSMISSION CASE PLUG

(a) Install the transmission case plug onto the manual transmission case with a new gasket.

Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)

41. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

(a) Using a (27 mm) deep socket wrench, install a new gasket and the back-up light switch to the manual transmission case.

Torque : 40 Nm (410 kgf-cm, 30 ft-lbf)

42. INSTALL MANUAL TRANSMISSION FILLER PLUG

(a) Install a new gasket and the manual transmission filler plug to the manual transmission case.

Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)

43. INSTALL MANUAL TRANSMISSION DRAIN PLUG

(a) Install a new gasket and the manual transmission drain plug to the front transaxle case.

Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)